Method and apparatus for processing an aerated confectionery foam rope

ABSTRACT

A method and system for processing at least one rope of aerated confectionery foam. The method includes extruding at least one rope of aerated confectionery foam from an extruder. The rope is conveyed from the extruder to a rotary cutter. An anti-sticking agent, such as powdered starch, is applied to the rope as the rope is conveyed from the extruder to the rotary cutter. Finally, the rope is cut into pieces with the rotary cutter. In one preferred embodiment, the rotary cutter is operated to perform at least 5,000 cuts per minute.

BACKGROUND OF THE INVENTION

[0001] The present invention relates to a food processing method andapparatus. More particularly, it relates to a method and apparatus forprocessing a rope of aerated confectionery foam, such as a marshmallowproduct, into small pieces on a mass production basis.

[0002] Aerated confections or aerated confectionery foams are popularfood items. Some aerated confectionery foams include a fat constituent,while others are substantially fat-free. An illustrative, fat-freeaerated confectionery foam is the common marshmallow. Such marshmallowproducts are familiar in both larger and smaller sizes.

[0003] It is well-known that such marshmallows when fresh are soft andpliable, but will stale by losing moisture and become hard. Indeed,purposefully pre-dried aerated confectionery foams are also well-known.These products, particularly in smaller or bit sizes, are popularlycommonly added to ready-to-eat (RTE) breakfast cereals, especially thosemarketed to children. Due to their small size (e.g., having a numbercount of 4-6 per gram), these dried, aerated confectionery marshmallowproducts are sometimes colloquially referred to as “Mar.” bits or“marbits”. The marbits must be pre-dried prior to admixture with the RTEcereal in order to reduce unwanted moisture migration from the marbit tothe cereal, and thus to forestall the multiple problems resultingtherefrom.

[0004] While there are many types of aerated confectionery marshmallowson the market, their methods of preparation generally fall into two mainprocess groups: extruded marshmallow and deposited marshmallow. Witheither type, a sugar syrup and a structuring agent such as an albumin,agar, or preferably a gelatin solution are the two main ingredients.Typically, the sugar syrup is cooled down and then combined with thegelatin solution to form a slurry. The slurry is then aerated to form afoam, and after aeration, desired colors and flavors can then be addedto the foam. Alternatively, the colorant can be added prior to aeration.Regardless, a single color can be used to produce a “simple” marbit, ormultiple colors in unequal proportions can be employed for a “complex”marbit. The particular marshmallow product may be formed into its finalshape by an extrusion process. That is, after aeration, the foam isextruded through die to form a rope. The die imparts the desiredperipheral shape (e.g. circle, square, star, irregular shape, etc.) tothe extrudate rope. The rope is allowed to rest briefly to stiffen, andthen is cut into desired sizes. For dried marshmallows, the process canadditionally include one or more drying steps as described, for example,in U.S. Pat. No. 4,785,551.

[0005] Substantial efforts have been made to optimize mass production ofaerated confectionery foam products, as well as to augment the resultingproduct. For example, U.S. patent Ser. No. xx/xxx,xxxx, filed on ______and entitled “Process For Aerated Confection” describes an improved massproduction technique for preparing candies and confections, especiallyaerated confections such as marshmallows. Additionally, for example,U.S. Pat. No. 5,019,404 and U.S. patent application Ser. No. xx/xxx,xxx,filed on ______ and entitled “Multi-Color Aerated Confectionery Productsand Processes for Making” both described techniques for formingmulti-colored marshmallow products for “complex” marbits on a massproduction basis.

[0006] While the above-described efforts have been successful achievinglow-cost, mass-produced simple and complex marbits, opportunities forfurther improvements remain. In particular, current processingtechniques virtually universally employ a guillotine-type verticalcutter for cutting the extrudate rope into small pieces. This apparatusis shown schematically, for example, in U.S. Pat. No. 5,019,404. Whilethe guillotine-type vertical cutter is undoubtedly serviceable, certaininherent limitations are presented. For example, the guillotine-typevertical cutter can simultaneously cut a number of extrudate ropesduring a single cutting cycle. However, each cutting cycle requires bothlowering and raising of the cutting blade, typically limiting themaximum number of cuts to less than 1,000 cuts per minute. Obviously,the maximum cuts per minute places an absolute limit on the number ofpieces a single cutter is able to produce. Additionally, the blade speedof the guillotine-type cutter during a cutting operation is relativelyslow, such that the extrudate rope must be allowed to “set” before acutting operation. As described in the above-referenced documents, theextrudate rope “sets” with cooling. Therefore, the extrudate rope mustbe allowed to cool for a relatively long period of time (or “residencetime”) prior to cutting. The relatively lengthy residence timerequirement, in turn, necessarily increases overall production time.Finally, for the same reasons, the guillotine-type vertical cuttercannot cut the extrudate rope into pieces smaller than approximately0.25 inch (6.35 mm) in thickness. Attempts to produce a smallerthickness marbit typically results in the marbit being deformed.

[0007] Aerated confectionery foam products, such as marshmallow ormarbits, continue to be extremely popular food items. As such,manufacturers will continue to produce large quantities of theseproducts, and therefore highly desire any available cost savings in themass production thereof. To this end, prior art processing techniquesincorporating a guillotine-type vertical cutter present certain inherentprocessing limitations. Therefore, a need exits for a method andapparatus for processing an aerated confectionery foam rope into smallpieces at increased rates.

SUMMARY OF THE INVENTION

[0008] One aspect of the present invention relates to a method ofprocessing at least one rope of aerated confectionery foam. The methodincludes extruding at least one rope of aerated confectionery foam froman extruder. The rope is then conveyed from the extruder to a rotarycutter. An anti-sticking agent is applied to the rope as the rope isconveyed from the extruder to the rotary cutter. Finally, the rope iscut into pieces with the rotary cutter. In one preferred embodiment, therotary cutter is operated to perform at least 5,000 cuts per minute.

[0009] Another aspect of the present invention relates to a system forprocessing at least one rope of aerated confectionery foam. The systemincludes an extruder, a conveyor and a rotary cutter. The extruder isconfigured to extrude at least one rope of aerated confectionery foam.The conveyor conveys the rope from the extruder, and terminates in aleading end. The rotary cutter device is positioned proximate theleading end of the conveyor. In this regard, the rotary cutter device isconfigured to cut the rope into pieces at a rate of at least 5,000 cutsper minute.

[0010] Yet another aspect of the present invention relates to a massproduced marbit flake to be added to a ready-to-eat cereal. The marbitflake is an aerated confectionery foam having a thickness of less than0.125 inch (3.175 mm). In one preferred embodiment, the marbit has athickness of approximately 0.0625 inch (1.5875 mm).

[0011] Yet another aspect of the present invention relates to a massproduced marbit flake to be added to a ready-to-eat cereal. The marbitflake is an aerated confectionery foam having a length:thickness aspectratio of in the range of approximately 32:5-48:5.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012]FIG. 1 is a schematic process flow diagram of a method ofpreparing an aerated confectionery foam product;

[0013]FIG. 2 is a schematic view of a system for processing an aeratedconfectionery foam rope in accordance with the present invention;

[0014]FIG. 3 is a side view of one preferred embodiment of a system forprocessing an aerated confectionery foam rope;

[0015]FIG. 4 is an enlarged view of a portion of the system of FIG. 3;

[0016]FIG. 5 is a cross-sectional view of an anvil support bar portionof FIG. 4;

[0017]FIG. 6A is a side view of a portion of a rotary cutter inaccordance with the present invention;

[0018]FIG. 6B is a top view of the rotary cutter of the FIG. 6A;

[0019]FIG. 7 is a top view of a blade used with the rotary cutter ofFIG. 6A;

[0020]FIG. 8 is a side view of a shroud used with the rotary cutter ofFIG. 6A; and

[0021]FIG. 9 is a process flow diagram of a method for processing anaerated confectionery foam rope.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0022] The present invention provides an improved method and apparatusfor processing an extruded rope of an aerated confectionery foam foodproduct, such as marshmallow, into small pieces or bits. Obviously,prior to processing in accordance with the present invention, theextrudate rope must be formed. Creation of an aerated confectionery foamrope can be done in a wide variety of fashions, detailed examples ofwhich are described in U.S. patent application Ser. No. xx/xxx,xxx,filed on ______ and entitled “process For Aerated Confection”; U.S.patent application Ser. No. xx/xxx,xxx, filed on ______ and entitled“Multi-Colored Aerated Confectionery Products And Processes For Making”;and U.S. Pat. No. 5,019,404 entitled “Multi-Color Confection ExtrusionSystem”, the teachings of which are incorporated herein by reference. Asa point of reference, FIG. 1 provides a schematic flow diagram of asimplified method for preparing an extrudate rope of aeratedconfectionery foam, it being understood that a number of variations tothe method shown in FIG. 1 can be employed and are well known in theart.

[0023] With the above background in mind, one embodiment of a method ofproducing an extrudate rope of aerated confectionery foam is referredgenerally in FIG. 1 by reference numeral 10. An essential first step 12includes forming a clear, concentrated sugar syrup. In one preferredembodiment, the syrup is an admixture of water and sugar, and a portionof corn syrup that is heated to sufficiently dissolve the sugar, but toavoid burning.

[0024] Following cooling of the syrup, a slurry is formed at step 14.The slurry is essentially an admixture of the syrup formed at step 12with a stabilizing or structuring agent, preferably a suitable gelatinagent (such as a gelatin-in-water solution or slurry). In one variation,the step 14 can optionally comprise admixing or seeding the slurry withsugar crystals. The sugar crystals can be seeded either to the slurry(i.e., after adding the gelatin structuring ingredient) or the sugarsyrup (i.e., before addition of the gelatin).

[0025] Where desired, a coloring agent, such as a food dye or colorant,may be added to the slurry at step 14. The colorant can be a finelydivided particulate, or preferably is a water soluble dye. As describedin the above references, the selected coloring agent can be added to asingle batch of slurry to produce a resulting aerated confectionery foamhaving that single color. Alternatively, several batches of slurry canbe formed to have different colors, and subsequently combined to producea multi-colored (or complex) rope. Alternatively, the coloring agent canbe added following aeration at step 16, or may be omitted entirely.

[0026] Aeration of the slurry occurs at step 16, such as by the additionof compressed gas. Aeration is well known in the art, and typicallyentails injection of nitrogen gas or clean air or other suitable gasinto the slurry.

[0027] The aeration step 16 forms an aerated confectionery foam streamor streams. One or more of the streams are fed to an extruder that, inturn, extrudes at least one extrudate rope of aerated confectionery foamat step 18. The resulting rope is plastic, characterized by a peripheralpattern or shape such as a circle, star, animal figure or other shapeincluding both regular or irregular shape as defined by the extruder.Depending upon the extrusion technique and the number of streamspresent, the extrudate rope can be uni-colored or multi-colored, havingvarious internal portions or pigments. By “plastic” is meant that thetemperature of the extrudate is above the set point temperature of thefoam structuring agent. As a result, the rope of extruded foam is easilydeformable at these elevated temperatures.

[0028] The extrudate rope is then conveyed from the extruder at step 20.As described in greater detail below, the conveying step 20 can becarried out by one or more conveyors (two are shown schematically inFIG. 1). The conveyor(s) have an overall length and are operated at afeed rate sufficient to allow the rope to at least partially cool, andtherefore at least partially “set” or solidify. Notable, a plurality ofextruders can simultaneously feed individual ropes onto the conveyor,such that a plurality of ropes are subsequently processedsimultaneously.

[0029] At step 22, prior to cutting or severing, the rope issubstantially uniformly coated with an anti-sticking agent, such aspowdered starch or a powdered starch-sugar mixture. The anti-stickingagent minimizes sticking of pieces during a subsequent cutting operationat step 24.

[0030] Cutting of the rope into multiple pieces at step 24 isfacilitated, in accordance with the present invention, with a rotarycutter. The rotary cutter is described in greater detail below. As apoint of reference, however, it is noted that prior art cuttingtechniques relied upon a guillotine-type reciprocating vertical cutter.With a rotary cutter of the present invention, overall cycle time isenhanced dramatically due to the increased number of cuts per minuteavailable.

[0031] Finally, after the rope(s) are cut into individual pieces, thepreparation of a dried aerated confectionery product, such as a marbit,includes a finish drying step 26 whereby each of the individual piecesare destarched and dried. Any suitable drying technique that will reducethe moisture content to about 2-4% is adequate. The resulting driedpieces can then be consumed as confections.

[0032] Once again, as is known in the art, the above process steps canbe varied widely and/or additional steps added to produce an extrudaterope or ropes of aerated confectionery foam. The method and apparatus ofthe present invention is focused upon processing of the rope(s)following extrusion.

[0033] In particular, FIG. 2 depicts schematically a system 30 forprocessing at least one rope of aerated confectionery foam 32. Thesystem 30 includes an extruder 34, a starch depositor 36, a conveyorsystem 38, a rotary cutter device 40 and a collection hopper or bin 42.The various components are described in greater detail below. Generallyspeaking, however, the conveyor system 38 delivers the rope 32 from theextruder 34 to the rotary cutter device 40. The starch depositor 36distributes a volume of an anti-sticking agent, such as powdered starch,on to the rope 32 prior to the rope 32 being engaged by the rotarycutter device 40. To this end, a leading end 44 of the conveyor system38 is positioned adjacent the rotary cutter device 40 and preferablyoperates in conjunction with a drive roller 46 for consistentlydirecting a length of the rope 32 to the rotary cutter device 40. Therotary cutter device 40 generally includes an anvil support bar 48 and arotary cutter 50. The rope 32 is directed from the conveyor system 38 tothe anvil support bar 48, which in turn properly positions a leadingportion 52 of the rope 32 relative to the rotary cutter 50. The rotarycutter 50 cuts or severs the rope 32 into small pieces 54 during acutting operation. The pieces 54 are collected within the hopper 42 andprepared for subsequent processing, such as drying.

[0034] The extruder 34 is of a type commonly known in the art, and caninclude a single or multiple stream manifold. The extruder 34 typicallyincludes an outlet die configured to impart a desired peripheral shapeto the rope 32. Further, the extruder 34 can be configured to produceone or more of the ropes 32.

[0035] Similarly, the starch depositor 36 is of a type commonly known inthe art. The starch depositor 36 is positioned above the conveyor system38 and is configured to coat the rope 32 with an anti-sticking agent,such as powdered starch. In this regard, a location of the starchdepositor along a length of the conveyor system 38 can be varied fromthat shown in FIG. 2.

[0036] The conveyor system 38 can assume a wide variety of forms, andcan include one or more independent, endless conveyor belts. Forexample, with reference to FIG. 2, the conveyor system 38 can include afirst conveyor 60 for receiving and conveying the rope 32 from theextruder 34, and a second conveyor belt 62positioned to receive the rope32 from the first conveyor 60 and deliver the rope 32 to the rotarycutter device 40. As is known in the art, this dual conveyor approachallows the conveyor belts associated with the conveyors 60, 62 to bemade of varying materials and to have varying delivery configurations.For example, FIG. 3 depicts one preferred embodiment of a portion of thesystem 30, and shows the conveyor system 38 as including the firstconveyor 60 (shown schematically) and the second conveyor 62. The secondconveyor 62 can be relatively shorter than the first conveyor 60, andincludes an endless belt 64 having a “roughened” surface. This roughenedattribute allows powdered starch distributed from the starch depositor36 to accumulate within the grooves (not shown) of the belt 64 forapplication of the powdered starch to a lower surface of the rope 32(FIG. 2). The conveyor 62 can incorporate side guards 66 (one of whichis shown in FIG. 3) for constraining movement of the rope 32 along awidth of the conveyor belt 64.

[0037] As a point of reference, FIG. 3 depicts the second conveyor 62and the rotary cutter device 40 as a unitary processing device 70,supported by a frame 72 and wheels 74. The wheels 74 allow theprocessing device 70 to be easily maneuvered to various locations, andtherefore can be used with any number of differently sized and locatedfirst conveyors 60. In one preferred embodiment, the conveyor 62associated with the processing device 70 is orientated within the frame72 to extend upwardly to the leading end 44 at an angle of approximately15° relative to horizontal. This preferred angular orientationfacilities subsequent engagement by the rotary cutter device 40Alternatively, other orientations can be employed, including ahorizontal position. Further, in one preferred embodiment, the conveyorbelt 64 has a conveying length of five feet (1.5 meters) and anavailable surface width of 20 inches (510 mm). Other dimensions, eithergreater or smaller, are equally acceptable

[0038] The leading end 44 of the conveyor 62, along with othercomponents, are shown in greater detail in FIG. 4. The conveyor 62 nestswithin the frame 72 and includes, in part, the endless belt 64 and apulley 80. The conveyor 62 operates in conjunction with the drive roller46 that includes a shaft 84. The leading end 44 of the conveyor 62 isdefined by the pulley 80. The drive roller 46 is positioned above theleading end 44 of the conveyor 62 such that a center axis of the driveroller 46 is aligned with a center axis of the pulley 80. Notably, thedrive roller 46 is preferably slightly spaced from the conveyor belt 64to provide a gap 84. In this regard, the shaft of 82 of the drive roller46 is connected to a vertical support plate 86, that in turn is securedto a support frame 88. The support frame 88 is attached to the frame 72to secure the drive roller 46 at a desired position relative to theframe 72 and thus the conveyor 62. Preferably, the vertical supportplate 86 is configured to be moveable relative to the support frame 88,such that a vertical position of the drive roller 46 relative to theconveyor belt 64 can be altered. With this feature, a size or height ofthe gap 82 is variable and can be selected in accordance with a size ofthe rope 32 (FIG. 2) being processed. In other words, an operator (notshown) can form the gap 82 to be slightly smaller than a height orthickness of the rope 32 such that the rope 32 is consistently anduniformly engaged by the conveyor 62/drive roller 46.

[0039] In a preferred embodiment, the drive roller 46 is rotated at aspeed corresponding with a speed of the conveyor 38. To this end, theprocessing device 70 preferably includes a timing mechanism, showngenerally at 90. The timing mechanism 90 comprises a timing belt 92 anda tension roller 94. The timing belt 92 articulates along and operablyassociates the pulley 80, the tension roller 94 and the drive roller 46.For example, each of the pulley 80, the tension roller 94 and the driveroller 46 can include toothed surfaces that are engageable by the timingbelt 92. Rotation of the pulley 80 (otherwise resulting in movement ofthe conveyor belt 64) by a motor (not shown) is translated to the timingbelt 92, causing the timing belt 92 to move. Movement of the timing belt92 is translated to the drive roller 46, via the tension roller 94, suchthat the drive roller 46 rotates at the same speed and in a rotationaldirection opposite that of the pulley 80. For example, where the pulley80 is driven in a clockwise direction, the tension roller 94 directs thetension belt 92 to contact and drive the drive roller 46 in acounter-clockwise direction. Importantly, the drive roller 46 is rotatedat the same speed as the pulley 30, and thus at a speed correspondingwith a speed or feed rate of the conveyor belt 64. Alternatively, othertiming mechanisms can be employed, whereby the drive roller 46 is drivenindependent of the conveyor 62.

[0040] The rotary cutter device 40 includes the anvil support bar 48,the rotary cutter 50, a shroud 100 (shown in phantom in FIG. 4 for easeof illustration) and a vacuum source (not shown). Each component of therotary cutter device 40 is described in greater detail below. Generally,however, the anvil support bar 48 presents and maintains the rope 32(FIG. 2) for the cutting by the rotary cutter 50. Th shroud 100 acts asa guard for the rotary cutter 50, and, along with the vacuum source,limits external dispersion of starch particles.

[0041] The anvil support bar 48 is positioned between the leading end 44of the conveyor 62 and the rotary cutter 50. The anvil support bar 48 isan elongated body, having a length slightly greater than a width of theconveyor 62. Thus, in one preferred embodiment, the anvil support bar 48has a length of 23.75 inches (600 mm), although other lengths areequally acceptable. As shown in greater detail in FIG. 5, the anvilsupport bar 48 is integrally formed from a rigid material, preferably304 stainless steel, and defines a top wall 102, a bottom wall 104, afirst side wall 106 and a second side wall 108. The top wall 102 ishighly flat for receiving the rope(s) 32 (FIG. 2), defining a preferredwidth of 2.75 inches (69.8 mm). The side walls 106, 108 extend betweenthe top wall 102 and the bottom wall 104. As a point of reference, thefirst side wall 106 is configured for placement adjacent the leading end44 (FIG. 4) of the conveyor 62 (FIG. 4), whereas the second side wall108 is configured for placement adjacent the rotary cutter 50 (FIG. 4).

[0042] With the above-described orientation of the anvil support bar 48in mind, the first side wall 106 preferably forms a recess 110. Therecess 110 is substantially concave, and is sized to provide clearancefor the leading end 44 (FIG. 4) of the conveyor 62 (FIG. 4). With thisconfiguration, the leading end 44 of the conveyor 62 extends within therecess 110 so that the top wall 102 is substantially contiguous with theconveyor 62 upon final assembly. Thus, the recess 110 is signed inaccordance with a radius of the pulley 80 (FIG. 4).

[0043] The second side wall 108 includes a guide surface 112 formed toextend from the top wall 102. During a cutting operation, the guidesurface 112 directs cut pieces (not shown) away from the top wall 102.As described below, a comer formed by the top wall 102 and the secondside wall 108 will be slightly spaced from the rotary cutter 50 (FIG. 4)to provide clearance for individual blades. However, due to the pliablenature of aerated confectionery foam, it may be possible for cut piecesto undesirably accumulate along the top wall 102. Thus, in one preferredembodiment, the guide surface 112 is recessed relative to a remainder ofthe second side wall 108. This recessed configuration limits a build-upof cut pieces from occurring adjacent or along the top wall 102 byproviding an increased clearance region for cut pieces to fall within.To this end, the guide surface 112 is preferably concave, therebypromoting rapid removal of cut pieces from the top wall 102.Alternatively, however, the guide surface 112 need not be recessed.

[0044] The rotary cutter 50, shown in greater detail in FIGS. 6A and 6B,includes a central shaft 120, housing plates 122, a plurality of back-upbars 124 and a plurality of blades 126. Generally speaking, the housingplates 122 are spaced along, and extend radially from, the central shaft120. Individual pairs of the back-up bars 124 and the blades 126,respectively, are secured to the housing plates 122.

[0045] The housing plates 122 are each integrally formed of a rigidmaterial, preferably 304 stainless steel. In one preferred embodiment,three of the housing plates 122 are provided, although any other number,either greater or smaller, can be employed. The housing plates 122extend radially from the central shaft 120, are preferably equidistantlyspaced, for example by approximately 9.75 inches (250 mm). The outer twoof the housing plates 122 define an overall cutting length of 20 inchesin one preferred embodiment. As best shown in FIG. 6A, each of thehousing plates 122 are generally circular discs, defining a plurality ofequidistantly spaced blade receiving regions 130. The number of bladereceiving regions 130 corresponds with the number of the blades 126.Thus, in one preferred embodiment, each of the housing plates 122 formeight of the blade receiving regions 130, equidistantly spaced by 45°.As a point of reference, during a cutting operation, it is desired thateach of the blades 126 engage and cut the rope 32 (FIG. 2) at a cuttingpoint (A in FIG. 6A). With this in mind, the blade receiving regions 130are configured to position a respective blade 126 at the cutting point Asuch that the blade 126 is substantially perpendicular to the rope 32(FIG. 2) being cut. Thus, in one preferred embodiment, each of the bladereceiving regions 130 form a 90° recess, although other configurationsare equally acceptable.

[0046] The back-up bars 124 are each integrally formed from a rigidmaterial, such as 17-4 stainless steel, and are sized to extend alongthe housing plates 122, having a preferred length of approximately 20inches (510 mm). Each of the back-up bars 124 are provided to define adesired spacing of one of the blades 126, respectively, from the housingplates 122. Thus, in one preferred embodiment, each of the back-up bars124 have a thickness of approximately 0.44 inch (11 mm), although otherdimensions may also be useful. Finally, each of the back-up bars 124 arepreferably configured so as to not interfere with the respective blades126 during a cutting operation. Thus, in one preferred embodiment, eachof the back-up bars 124 taper from an outer surface thereof, inaccordance with a cutting angle formed by the respective blade 126(described below), between each of the housing plates 122 (as best shownin FIG. 6B).

[0047] With reference to FIG. 6A and 7, each of the blades 126 extendalong a perimeter of the housing plates 122. As best shown in FIG. 7,each of the blades 126 defines a material face 140, a rake face 142 anda guide face 144. The material face 140 and the rake face 142 combine toform a cutting angle α. The cutting angle α is preferably in the rangeof approximately 20°-50°, more preferably in the range of 30°-40°. Inone preferred embodiment, the cutting angle α is 36°. As described ingreater detail below, each of the blades 126 are secured to the housingplates 122 (FIG. 6A) such that the blades 126 interact with and cut therope 32 (FIG. 2) in the cutting position shown in FIG. 7. Thus, in apreferred embodiment, each of the blades 126 are formed such that in thecutting position, the material face 140 and the guide face 144 aresubstantially perpendicular to the rope 32 so as to form a relativelyuniform cut piece.

[0048] Each of the blades 126 are integrally formed from a rigidmaterial, preferably heat treated 17-4 stainless steel. Other rigidmaterials, such as plastic or ceramic, can alternatively be employed.Due to the relatively high rate at which the blades 126 will cut throughan aerated confectionery foam rope, it is preferred that the materialselected for the blade 126 cause a small amount of friction to occurbetween the guide face 144 and the aerated confectionery foam being cut.With this preferred design characteristic, the cut piece willtemporarily adhere to the guide face 144 so that the guide face 144 cancarry the cut piece away (downwardly relative to the orientation of FIG.7.) from the rope 32 (FIG. 2). Without this preferred frictionalinteraction, the cut piece may fly upwardly and undesirably contactanother one of blades 126. Conversely, however, the material face 140 ispreferably configured to limit material build-up. Thus, in one preferredembodiment, the material face 140 is coated is an anti-stick material,such as bees wax.

[0049] Each of the blades 126 are preferably sized in accordance with aclearance provided by the blade receiving zones 130 (FIG. 6A). Forexample, in one preferred embodiment, each of the blades 126 has a widthof 1.55 inches (39.4 mm) and a thickness of 0.188 inch (4.77 mm),although other dimensions are equally acceptable. Further the blades 126can be formed to a greater thickness, thereby eliminating a need for therespective back-up bars 124 (FIG. 6A).

[0050] Finally, one preferred embodiment of the shroud 100 is shown inFIG. 8. The shroud 100 is configured to encompass the rotary cutter 50(FIG. 4), and preferably includes a visual inspection plate 150. Theviewing plate 150 is clear for viewing of the rotary cutter 50 duringoperation. The shroud 100 serves to not only guard against potentialoperator injuries during operation of the rotary cutter 50, but also tocapture starch dust. To this end, and as described in greater detailbelow, a negative pressure is preferably created within the shroud 100by the vacuum source (not shown) to collect starch dust.

[0051] With reference to FIG. 4, assembly of the processing device 70 issubstantially as follows. The rotary cutter 50 is first assembled bysecuring the housing plates 122 to the central shaft 120. The housingplates 122 are equidistantly spaced along the central shaft 120,preferably by a distance of approximately 9.75 inches. With thisspacing, the outer two housing plates 122 define a preferred overallcutting length of approximately 20 inches. When properly assembled, therespective blade receiving zones 130 of the housing plates 122 arealigned. Individual pairs of the back-up bars 124 and the blades 126 arethen assembled to the housing plates 122. For example, one of the backupbars 124 is placed within one aligned set of the blade receiving zones130. One of the blades 126 is placed on top of the previously placedback-up bar 126. The two components are then secured to the housingplates 122. For example, bolts can be used to secure respective pairs ofthe back-up bars 124 and the blades 126 to the housing plates 122.

[0052] The assembled rotary cutter 50 is then secured to the frame 72.The anvil support bar 48 and the conveyor 62 are similarly secured tothe frame 72. In one preferred embodiment, the anvil support bar 48 ispositioned as close as possible to the rotary cutter 50, while stillallowing for clearance of the blades 126. In this regard, a slightclearance of 0.005 inch (0.127 mm) is preferably provided between thetop wall 102 (shown best in FIG. 6) of the anvil support bar 48 and therotary cutter 50. The shroud 100 is secured over the rotary cutter 50.In a preferred embodiment, the vacuum source (not shown) is fluidlyconnected to an interior of the shroud 100. During use, the vacuumsource creates a negative pressure within the shroud 100 to removestarch dust generated during operation of the rotary cutter 50. Finally,the starch depositor 36 is secured over the conveyor 62

[0053] Following assembly, the processing device 70 is used to processat least one extrudate rope of aerated confectionery foam, as shownschematically in FIG. 3 and diagrammatically in FIG. 9. The at least onerope 32 is extruded from the extruder 34 at step 150. The rope 32 isconveyed from the extruder 34 by the conveyor system 38 at step 152. Aspreviously described, the conveyor system 38 can be comprised of one ormore individual conveyors, such as the conveyors 60, 62. Regardless, theconveyor system 38 has an overall length (defined as a distance from anexit of the extruder 34 to the anvil support bar 48) and an operationalspeed configured to allow the rope 32 to partially set slightly during aresidence time period (e.g. time period from extrusion to cutting). Inone preferred embodiment, the conveyor system 38 is operated at a feedrate of 100 feet per minute (30.5 meters per minute) and has an overalllength of less than 100 feet(30.5 meters) so as to provide a residencetime period of less than sixty seconds. More preferably, the conveyorsystem 38 has a length of less than 42 feet (12.8 meters) so as toprovide a residence time period of less than twenty-five seconds. Evenmore preferably, the conveyor system 38 has an overall length ofapproximately 36.7 feet (11.2 meters) so as to provide a residence timeperiod of twenty-two seconds. Obviously, the conveyor system 38 can beoperated at different feed rates and/or have different lengths toprovide a residence time period of less than sixty seconds, morepreferably less than twenty-five seconds, most preferably twenty-twoseconds. Even further, the conveyor system 38 can be configured toprovide a residence time period of less than twenty-two seconds. In thisregard, due to the elevated cutting rate available with the rotarycutter 50 (described below), it is possible that the rope 32 will need aresidence time period of only a few seconds, and still be properly cut.

[0054] As the rope 32 is conveyed from the extruder 34, an anti-stickingagent, such as powdered starch, is applied to the rope 32 by the starchdepositor 36 at step 154. The powdered starch is preferably applied justprior to engagement of the rope 22 by the rotary cutter device 40. As isknown in the art, the starch depositor 36 is positioned along a lengthof the conveyor system 38 such that the powdered starch is appliedapproximately two seconds prior to a cutting operation, although otherlocations are equally acceptable. The powdered starch is preferablyapplied at a volumetric rate sufficient to accommodate a conveyor feedrate of 100 feet per minute (30.5 meters per minute). Thus, in onepreferred embodiment, the starch depositor 36 releases approximately 20pounds per minute of the powdered starch where a single rope 32 is beingprocessed. Additional volume of starch is required where a plurality ofropes 32 are simultaneously processed. For example, for simultaneousprocessing of ten of the ropes 32, the starch is applied at a rate ofapproximately 200 pounds per minute. It will be recalled that theportion of the conveyor system 38 beneath and down stream of the starchdepositor 36 (such as the conveyor 62) preferably includes a “roughened”conveyor belt able to retain starch and therefore distribute starch to abottom side of the rope 32.

[0055] As the rope 32 nears the leading end 44 of the conveyor system38, the rope 32 is engaged by the drive roller 46 at step 156. Aspreviously described, the drive roller 46 is driven at a speedcorresponding with that of the conveyor system 38. Further, the gap 84formed by the drive roller 46 and the conveyor system 38 is selected inaccordance with a thickness of the rope 32. Thus, the operator (notshown) can maneuver the drive roller 46 to provide a gap 84 slightlysmaller than a thickness of the rope 32. As the rope 32 enters the gap84, the drive roller 46 and the conveyor system 38 engage and direct therope 32 toward the rotary cutter device 40.

[0056] At step 158, the rope 32 passes from the conveyor system 38 tothe top wall 102 of the anvil support bar 48. The anvil support bar 48maintains the rope 32 at a level for optimal cutting by the rotarycutter 50.

[0057] At step 160, the rotary cutter 50 cuts the rope 32 into thepieces 54. The rotary cutter 50 is preferably operated to perform atleast five thousands cuts per minute. Thus, in the preferred embodiment,where the rotary cutter 50 includes eight of the blades 126, the rotarycutter 50 is rotated at a rate of 625 revolutions per minute. Obviously,where the rotary cutter 50 includes a different number of the blades126, the rotary cutter 50 is rotated at a correspondingly differentrate. Notably, the rotary cutter 50 will generate a large amount ofstarch dust during the cutting operation. While the rotary cutter device40 is preferably provided with the shroud 100 and a negative pressurefor containing and removing this starch dust, experiments have shownthat at extremely high rotational speeds, the amount of starch dust willexceed the collection capabilities of the rotary cutter device 40. Acomparison of available cutting speed with dust generation has revealedan optimal configuration of the rotary cutter 50 to include eight of theblades 126 and an operational speed of 625 revolutions per minute.

[0058] The individual pieces 54 cut from the rope 32 are directed by therotary cutter 50 to the hopper 42 at step 162. The hopper 42 preferablyincludes a screen (not shown) that collects the pieces 54, yet allowsthe starch dust to pass through. With this approach, the hopper 42effectively separates starch from the pieces 54 of confection. In onepreferred embodiment, to assist in this separation, the hopper 42vibrates, such that the hopper 42 may include an orbital vibrationdevice.

[0059] The method and apparatus of the present invention efficientlyprocesses one or more ropes 32 of aerated confectionery foam into smallpieces, for example marbits. Due to the speed at which the rope 32 iscut via the rotary cutter 50, individual pieces or marbits can be formedhighly thin as compared to previous mass-production techniques. That isto say, prior art guillotine-type vertical cutters cannot produceindividual pieces or marbits having a thickness of less than 0.25inch.This limitation is due in large part to the relatively slow speed of thevertical cutter, as well as the deformation characteristics of theaerated confectionery foam rope. Simply stated, during a cuttingoperation with a guillotine-type vertical cutter, the aeratedconfectionery foam material will deform and stretch outward. In directcontrast, the rotary cutter and related method of the present inventionprovides for a greatly increased cutting speed at which only minimal, ifany, rope deformation occurs. Therefore, by altering either the feedrate of the conveyor or the cutting (or rotational) rate of the rotarycutter, the method and apparatus of the present invention can produce anaerated confectionery foam piece (or marbit) having a thickness of lessthan 0.25inch (6.35 mm), preferably less than 0.125inch (3.175 mm), andeven more preferably approximately 0.0625inch (1.587 mm). As a point ofreference, marbits normally included with ready-to-eat cereals have athickness of approximately 0.25inch (6.35 mm) and a maximum length of0.4-0.6inch (10.2-15.2 mm) (it being recalled that individual marbitsmay assume a wide variety of shapes). Stated otherwise, currentlyavailable marbits used with ready-to-eat cereals have a length:thicknessaspect ratio in the range of approximately 8:5-12:5. The method andapparatus of the present invention can produce similarly configuredmarbits. Additionally, however, the method and apparatus of the presentinvention can produce marbits having a length:thickness aspect ratio inthe range of approximately 16:5-48:5; more preferably in the range of32:5-48:5.

[0060] The method and apparatus of the present invention provides amarked improvement over previous processing techniques by incorporatinga rotary cutter to cut a rope of aerated confectionery foam into smallpieces. Overall production capabilities are greatly enhanced due to theincreased number of cuts that can be performed with the rotary cutter.Further, the rotary cutter facilitates a greatly reduced residence timeperiod for the rope, again improving production cycle time. Finally,marbit flakes of reduced thickness can be consistently manufactured on amass production basis.

[0061] Although the present invention has been described with referenceto preferred embodiments, workers skilled in the art will recognize thatchanges can be made in form and detail without departing from the spiritand the scope of the present invention. For example, the method andapparatus of the present invention has been described with reference toprocessing of a single rope of aerated confectionery foam.Alternatively, a number of ropes can simultaneously be processed,thereby increasing overall productivity. For example, the method andapparatus of the present invention can be used to process ten or twentyropes simultaneously. Additionally, throughout this specification,certain dimensions have been ascribed to various components, spacings,etc. Where provided, these specific dimensions relate to one preferredembodiment of the preferred system and related method. That is to say, awide variety of other dimensions can alternatively be employed.

What is claimed is:
 1. A method of processing at least one rope of aerated confectionery foam, the method comprising: extruding at least one rope of aerated confectionery foam from an extruder; conveying the rope from the extruder to a rotary cutter; applying an anti-sticking agent to the rope as the rope is conveyed from the extruder to the rotary cutter; and cutting the rope into pieces with the rotary cutter.
 2. The method of claim 1, wherein the rope is conveyed from the extruder to the rotary cutter over a residence time period of less than 60 seconds.
 3. The method of claim 2, wherein the residence time period is less than 25 seconds.
 4. The method of claim 3, wherein the residence time period is approximately 22 seconds.
 5. The method of claim 1, wherein the anti-sticking agent is powdered starch.
 6. The method of claim 5, wherein applying the powdered starch includes distributing 20-25 pound s of powdered starch per minute for a single rope of aerated confectionery foam.
 7. The method of claim 1, wherein conveying the rope includes conveying the rope at a speed of at least 100 feet per minute.
 8. The method of claim 1, wherein cutting the rope includes operating the rotary cutter to perform at least 5,000 cuts per minute.
 9. The method of claim 8, wherein the rotary cutter includes eight blades secured about a perimeter of a support plate, and further wherein operating the rotary cutter includes rotating the support plate at a speed of 625 rpm.
 10. The method of claim 1, further comprising: engaging the rope between a drive roller and a conveyor proximate the rotary cutter.
 11. The method of claim 10, further comprising: operating the drive roller at a rotational speed corresponding with a feed rate of the conveyor.
 12. The method of claim 1, wherein cutting the rope with the rotary cutter includes forming pieces having a thickness of less than 0.125 inch.
 13. The method of claim 1, wherein cutting the rope with the rotary cutter includes forming pieces having a length:thickness aspect ratio in the range 32:5-48:5.
 14. The method of claim 1, wherein extruding the rope includes forming a plastic extrudate.
 15. The method of claim 1, wherein extruding the rope includes forming a heated extrudate.
 16. The method of claim 1, wherein extruding the rope includes forming a deformable extrudate.
 17. A system for processing at least one rope of aerated confectionery foam, the system comprising: an extruder configured to extrude at least one rope of aerated confectionery foam; a conveyor for conveying the rope from the extruder, the conveyor terminating in a leading end; and a rotary cutter positioned proximate the leading end of the conveyor, the rotary cutting being configured to cut the rope into pieces at a rate of at least 5,000 cuts per minute during a cutting operation.
 18. The system of claim 17, further comprising: an anvil support bar positioned between the leading end of the conveyor and the rotary cutter, the anvil support bar configured to maintain the rope during the cutting operation.
 19. The system of claim 18, wherein the anvil support bar is an elongated body including a top wall for receiving the rope, a bottom wall, and first and second opposing side walls extending between the bottom and top walls, the anvil support bar being positioned such that the first side wall is adjacent the leading end of the conveyor and the second side wall is adjacent the rotary cutter.
 20. The system of claim 19, wherein the first side wall is concave to provide clearance for the leading end of the conveyor.
 21. The system of claim 19, wherein the second side wall is configured to provide a guide surface for directing a piece cut from the rope away from the rope.
 22. The system of claim 21, wherein the guide surface is recessed relative to a remainder of the second side wall.
 23. The system of claim 19, wherein the anvil cutter bar is positioned such that a comer formed by the top wall and the second side wall is spaced approximately 0.005 inch from the rotary cutter.
 24. The system of claim 17, further comprising: a drive roller located above the leading end of the conveyor, the drive roller and the conveyor forming a gap sized to engage the rope.
 25. The system of claim 24, wherein a height of the gap is variable.
 26. The system of claim 24, wherein the drive roller and the conveyor act in concert to direct the rope to the rotary cutter.
 27. The system of claim 26, further including: a timing mechanism for correlating a speed of the conveyor with a speed of the drive roller.
 28. The system of claim 17, further comprising: starch depositor located between the extruder and the rotary cutter for applying powdered starch to the rope.
 29. The system of claim 28, further comprising a shroud surrounding the rotary cutter for capturing starch dust generated during a cutting operation.
 30. The system of claim 29, further comprising a vacuum source fluidly connected to the shroud for creating a negative pressure within the shroud.
 31. The system of claim 17, wherein the rotary cutter includes a plurality of elongated blades equidistantly spaced along a perimeter of at least one housing plate.
 32. The system of claim 31, wherein the rotary cutter includes 8 blades.
 33. The system of claim 31, wherein each of the plurality of blades include a material face, a rake face and a guide face, the material face and the rake face combining to define a cutting angle in the range of approximately 25°-45°.
 34. The system of claim 33, wherein the cutting angle is approximately 35°.
 35. The system of claim 33, wherein each of the plurality of blades are secured to the at least one housing plate such that the material face is substantially perpendicular to the rope during the cutting operation.
 36. A mass produced marbit flake comprised of an aerated confectionery foam and having a thickness of less than 0.125 inch.
 37. The marbit flake of claim 36 having a thickness of approximately 0.0625 inch.
 38. The marbit flake of claim 36, wherein the marbit flake has a shaped periphery.
 39. A mass produced marbit flake comprised of an aerated confectionery foam and having a length:thickness aspect ratio in the range of approximately 32:5-48:5.
 40. The marbit flake of claim 39, wherein the marbit flake has a shaped periphery. 